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Lincoln Electric RANGER 11458, Operator'S Manual

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Lincoln Electric RANGER 11458 Operator'S Manual Download Page 1

Ranger

®

305D (CE)

OPERATORʼS MANUAL

IM971-A

June, 2010

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. 

DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ-
ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON-
TAINED THROUGHOUT.

And,

most importantly, think before
you act and be careful.

For use with machines having Code Numbers:

11458, 11459, 11587

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199  U.S.A.   TEL: 216.481.8100   FAX: 216.486.1751   WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

EN 60974-1

Copyright ©  Lincoln Global Inc.

Summary of Contents for RANGER 11458

Page 1: ...OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READ ING THIS MANUAL AND THE SAFETY PRECAUTIONS CON TAINED THROUGHOUT And most importantly think before you act and be careful For use with machines having Code Numbers 11458 11459 11587 Sales and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s...

Page 2: ...AKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING Read and understand the following safety highlights For additional safety information it is strongly recommended that you purchase a copy of Safety in Welding Cutting ANSI Standard Z49 1 from the American Welding Society P O Box 351040 Miami Florida 33135 or CSA Standard W117 2 1974 A Free copy of Arc Welding Safety booklet E205 is ava...

Page 3: ...or cooling 3 h Never simultaneously touch electrically hot parts of electrode holders connected to two welders because voltage between the two can be the total of the open circuit voltage of both welders 3 i When working above floor level use a safety belt to protect yourself from a fall should you get a shock 3 j Also see Items 6 c and 8 FUMES AND GASES can be dangerous 5 a Welding may produce fu...

Page 4: ...s to adjacent areas Avoid welding near hydraulic lines Have a fire extinguisher readily available 6 b Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Welding and Cutting ANSI Standard Z49 1 and the operating information for the equipment being used 6 c When not welding make certain no part of the electrode ...

Page 5: ...riés et non inflamma bles 4 Des gouttes de laitier en fusion sont émises de lʼarc de soudage Se protéger avec des vêtements de protection libres de lʼhuile tels que les gants en cuir chemise épaisse pantalons sans revers et chaussures montantes 5 Toujours porter des lunettes de sécurité dans la zone de soudage Utiliser des lunettes avec écrans lateraux dans les zones où lʼon pique le laitier 6 Elo...

Page 6: ... installed power 2 3 Rated speed r p m 6 4 04 0 4 4 0 0 5 2 3 0 0 0 6 0 6 1 7 8 8 0 3 0 0 04 0 4 0 0 6 9 8 6 4 0 0 04 8 0 0 6 0 04 06 1 8 04 0 6 4 04 0 4 1 0 0 04 0 0 04 0 8 04 0 8 04 0 1 0 0 0 6 04 6 04 0 04 0 061 04 0 04 4 0 6 4 0 0 1 2 3 4 2 5 6 4 1 2 7 8 9 6 1 2 3 2 5 2 4 84 9 4 4 7 1 3 0 0 0 04 0 8 6 04 0 4 0 6 3 0 3 ...

Page 7: ...r use outdoors 2000 14 EC Annex VI procedure 1 Standards EN 50199 Electromagnetic compatibility EMC product standard for arc welding equipment 1995 A1 EN 60974 1 Safety requirements for arc welding equipment power sources 1998 A1 EN ISO 3744 Acoustic ñ Determination of sound power levels of noise sources using sound pressure Ö 1995 Notified body for 2000 14 EC Conformity LNE ñ Number 0071 Address ...

Page 8: ...e the situation with the technical assistance of the manufacturer In some cases this remedial action may be as simple as earthing grounding the welding circuit see Note In other cases it could involve construction of an electromagnetic screen enclosing the power source and the work complete with associated input filters In all cases electromagnetic disturbances must be reduced to the point where t...

Page 9: ...tions Welding Cables The welding cables should be kept as short as possible and should be positioned close together running at or close to floor level Equipotential Bonding Bonding of all metallic components in the welding installation and adjacent to it should be considered However metallic components bonded to the work piece will increase the risk that the operator could receive a shock by touch...

Page 10: ... important when identifying the correct replacement parts On Line Product Registration Register your machine with Lincoln Electric either via fax or over the Internet For faxing Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it For On Line Registration Go to our WEB SITE at www lin...

Page 11: ...nection of Lincoln Electric Wire Feeders A 6 A 7 ________________________________________________________________________________ Operation Section B Safety Precautions B 1 General Description B 1 For Auxiliary Power B 1 Engine Operation B 1 Break in Period B 1 Add Fuel B 1 Fuel B 1 Welder Controls B 2 Engine Controls B 3 Starting and Stopping the Engine B 3 B4 Stopping B 4 Welding Operation B 5 D...

Page 12: ...gine Adjustment D 5 Battery Maintenance D 5 Servicing Optional Spark Arrestor D 5 Welder Generator Maintenance D 6 Storage D 6 Cleaning D 6 Brush Removal and Replacement D 6 ________________________________________________________________________ Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 thru E 6 _______________________________________________________...

Page 13: ...ical Fuel Pump Auto air bleed with Full Flow Filter EPA Tier 4 system Electric shutoff solenoid Indirect fuel injector Mechanical Governor Compliant AIR CLEANER ENGINE IDLER MUFFLER ENGINE PROTECTION Low noise Muffler Shutdown on low oil Single Element Automatic Idler Made from long life aluminized steel pressure engine temperature ENGINE WARRANTY 2 year complete parts and labor 3rd year major com...

Page 14: ...n unrestrict ed flow of clean cool air to the cooling air inlets and to avoid restricting the cooling air outlets Also locate the welder so that the engine exhaust fumes are properly vented to an outside area STACKING RANGER 305D CE machines cannot be stacked ANGLE OF OPERATION Engines are designed to run in the level condition which is where the optimum performance is achieved The maximum angle o...

Page 15: ...gine Keep sparks and flame away from tank OIL The machine is shipped with the engine crankcase filled with high quality SAE 10W 30 Oil that meets classification CG 4 or CH 4 for diesel engines Check the oil level before starting the engine If it is not up to the full mark on the dip stick add oil as required Check the oil level every four hours of running time during the first 50 running hours Ref...

Page 16: ...d with a 6 pin and a 14 pin connector The 6 pin connector is for connecting the K857 or K857 1 Remote Control or for TIG welding the K870 foot Amptrol or the K963 3 hand Amptrol When in the CC STICK DOWNHILL PIPE or CV WIRE modes and when a remote control is connected to the 6 pin Connector the auto sensing circuit auto matically switches the OUTPUT control from control at the welder to remote con...

Page 17: ...e to a premises or resi dential electrical system Be certain that A 5 INSTALLATION RANGER 305D CE A 5 When this welder is mounted on a truck or trailer its frame must be electrically bonded to the metal frame of the vehicle Use a 8 or larger copper wire connected between the machine grounding stud and the frame of the vehicle When this engine driven welder is connect ed to premises wiring such as ...

Page 18: ...2 seconds unless welding is resumed If you are using an LN 25 without an internal con tactor the electrode will be energized when the RANGER 305D CE is started WARNING CAUTION The installation complies with the National Electrical Code and all other applicable electri cal codes The premises is isolated and no feedback into the utility system can occur Certain laws require the premises to be isolat...

Page 19: ...A 7 INSTALLATION RANGER 305D CE A 7 Connection of LN 742 and Cobramatic to RANGER 305D CE Shut the welder off Connect per instructions on the appropriate connec tion diagram in Section F ...

Page 20: ...ngine Be sure the machine is on a level surface Open top side engine doors and remove the engine oil dipstick and wipe it with a clean cloth Reinsert the dipstick and check the level on the dip stick Add oil if necessary to bring the level up to the full mark Do not overfill Close engine door Check radiator for proper coolant level Fill if nec essary See Engine Ownerʼs Manual for specific oil and ...

Page 21: ...ge con trol capability when the control cable is connected to the 14 Pin Connector the auto sensing circuit automatically makes OUTPUT CONTROL inactive and the wire feeder voltage control active When in the TOUCH START TIG mode and when a Amptrol is connected to the 6 Pin Connector the OUT PUT control is used to set the maximum current range of the CURRENT CONTROL of the Amptrol 2 DIGITAL OUTPUT M...

Page 22: ...circuit auto sensing remote control circuit and 42V power The remote control circuit operates the same as the 6 Pin connector Note The 14 pin connector does not include 120V 8 6 PIN CONNECTOR For attaching optional remote control equipment Includes auto sensing remote control circuit 9 WELD TERMINALS SWITCH In the WELD TERMI NALS ON position the output is electrically hot all the time In the REMOT...

Page 23: ... idle for several minutes before applying a load and or switching to high idle Allow a longer warm up time in cold weather NOTE If the unit fails to start repeat step 4 through step 7 after waiting 30 seconds Do not allow the starter motor to run continuously for more than 20 seconds Do not push the START button while the engine is running because this can damage the ring gear and or the starter m...

Page 24: ...OL dial adjusts the full output range for stick welding The ARC CONTROL dial sets the short circuit current arc force during stick welding to adjust for a soft or crisp arc Increasing the dial from 10 soft to 10 crisp increases the short circuit current and prevents sticking of the elec trode to the plate while welding This can also increase spatter It is recommended that the ARC CONTROL be set to...

Page 25: ...set the maximum range of the CURRENT CONTROL on the TIG module or an Amptrol if connected to the TIG Module See Table B 2 WIRE WELDING CV Connect a wire feeder to the RANGER 305D CE according to the instructions in INSTALLATION INSTRUCTIONS Section The RANGER 305D CE in the CV WIRE mode per mits it to be used with a broad range of flux cored wire Innershield and Outershield electrodes and solid wi...

Page 26: ... 9 m 30 ft of work cable head shield work clamp electrode holder Cables are rated at 400 amps 100 duty cycle K857 7 6m 25 ft or K857 1 30 4m 100 ft REMOTE CONTROL Portable control provides same dial range as the output control on the welder Has a convenient 6 pin plug for easy connection to the welder RANGER 305D CE ...

Page 27: ...MPONENTS KUBOTA D722 DIESEL ENGINE KUBOTA D722 DIESEL ENGINE Service Intervals Observe the following for service and maintenance The lubricating oil change intervals listed in the table below are for Classes CF CE and CD lubricating oils of API classification with a low sulfur fuel in use If the CF 4 or CG 4 lubricating oil is used with a high sulfur fuel change the lubricating oil at shorter inte...

Page 28: ...CF CF 4 CG 4 or CH 4 ACEA E1 E2 E3 Always check the API service label on the oil container to be sure it includes the letters indicated Note An S grade oil must not be used in a diesel engine or damage may result It IS permissible to use an oil that meets S and C grade service classifi cations SAE 10W30 is recommended for general all tempera ture use 15C to 40C 5F to 104F See engine ownerʼs manual...

Page 29: ...D 3 MAINTENANCE D 3 RANGER 305D CE ...

Page 30: ...T If the fan belt is loose the engine can overheat and the battery lose its charge Check tightness by press ing on the belt midway between the pulleys It should deflect about 6mm 25 in under a load of 9 Kg 20 lbs FUEL At the end of each dayʼs use refill the fuel tank to min imize moisture condensation and dirt contamination in the fuel line Do not overfill leave room for the fuel to expand Use onl...

Page 31: ...irty If the terminals appear corroded discon nect the battery cables and wash the terminals with an ammonia solution or a solution of 113g 1 4 pound of baking soda and 0 9461L 1 quart of water Be sure the battery vent plugs if equipped are tight so that none of the solution enters the cells After cleaning flush the outside of the battery the bat tery compartment and surrounding areas with clear wa...

Page 32: ...es and slip rings to wear and darken slightly Inspect the brushes when a generator over haul is necessary Do not attempt to polish slip rings while the engine is running WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed on this equip ment may result in danger to the technician and machine operator and will invalidate yo...

Page 33: ...BLE CAUSE lists the obvious external possibilities that may contribute to the machine symptom Step 3 RECOMMENDED COURSE OF ACTION This column provides a course of action for the Possible Cause generally it states to contact your local Lincoln Authorized Field Service Facility If you do not understand or are unable to perform the Recommended Course of Action safely contact your local Lincoln Author...

Page 34: ...vertical position of handle 2 Fuel Filters dirty clogged Check and replace main filter element and or Inline Fuel Filter 3 Out of fuel Fill tank and bleed fuel system 4 High coolant temperature or low oil pressure indictor lights lit Check oil and coolant levels Fill if required Check for loose or bro ken fan belt 5 Faulty fuel shutdown solenoid Check that shutdown solenoid is functioning properly...

Page 35: ...nd exhaust end case back 1 Dirty fuel or air filters Inspect and clean replace filters as needed Inspect and clean replace filters as needed 2 Water in fuel If water found in tank Empty fuel tank and refill then purge fuel lines 1 Faulty battery Replace 2 Loose connections at battery or alternator Clean and tighten con nections 3 Faulty engine alternator or charg er module Consult authorized Engin...

Page 36: ...nt linkage or broken spring 1 Fuel filter clogged Replace 2 Air filter clogged clean or replace 3 High idle setting incorrect check and adjust if required 4 Valves out of adjustment 5 Fuel contaminated with water or sediment Check fuel pre filter and empty of water bleed fuel system Replace fuel in tank if needed 1 Broken spring on Idle Solenoid solenoid linkage binding Faulty PC board low idle sp...

Page 37: ...ition Place switch in Weld Terminals On position when welding without control cable 3 Faulty PC board 1 Poor remote control cable connec tion to 6 pin or 14 pin connector Check connections 2 Faulty remote cable or faulty wire feeder or wire feeder cable Replace if necessary 3 Faulty control potentiometer or PC board 1 Wire Feeder Power circuit breaker open Check 42V beaker and reset if tripped 2 F...

Page 38: ...s not stable or is not satis factory the engine runs normally The auxiliary power is normal 1 Make sure the MODE selector switch is in the correct position for the process being used For exam ple CV WIRE PIPE CC STICK 2 Make sure the electrode wire gas voltage current etc is correct for the process being used 3 Check for loose or faulty connec tions at the weld output terminals and welding cable c...

Page 39: ...F 1 DIAGRAMS F 1 RANGER 305D CE ...

Page 40: ...F 2 DIAGRAMS F 2 RANGER 305D CE ...

Page 41: ...F 3 DIAGRAMS F 3 RANGER 305D CE ...

Page 42: ...F 4 DIAGRAMS F 4 RANGER 305D CE ...

Page 43: ...F 5 DIAGRAMS F 5 RANGER 305D CE ...

Page 44: ...It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 45: ...It may not be accurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Department for a replacement Give the equipment code number ...

Page 46: ...R 305D CE A M21086 60 21 1529 3 29 67 753 6 60 00 1524 0 59 20 1503 7 17 50 444 5 19 50 495 3 21 06 534 9 21 50 546 1 29 83 757 6 34 24 869 8 11 03 280 2 29 63 752 6 17 00 431 8 CENTER OF GRAVITY 35 08 891 03 26 52 673 6 6 33 160 9 ...

Page 47: ...NOTES RANGER 305D CE ...

Page 48: ...NOTES RANGER 305D CE ...

Page 49: ...NOTES RANGER 305D CE ...

Page 50: ... electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes o los electrodos bajo carga con la piel o ropa moja da Aislese del trabajo y de la tierra Ne laissez ni la peau ni des vête ments mouillés entrer en contact avec des pièces sous tension Isolez vous du travail et de la terre Berühren Sie keine stromführenden Teile oder Elektrod...

Page 51: ... gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öffnen Maschine anhalten Não opere co...

Page 52: ...s and Service through Subsidiaries and Distributors Worldwide Cleveland Ohio 44117 1199 U S A TEL 216 481 8100 FAX 216 486 1751 WEB SITE www lincolnelectric com World s Leader in Welding and Cutting Products ...

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